WO2018061797A1 - 金属製立体構造物の表面処理方法 - Google Patents
金属製立体構造物の表面処理方法 Download PDFInfo
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- WO2018061797A1 WO2018061797A1 PCT/JP2017/033243 JP2017033243W WO2018061797A1 WO 2018061797 A1 WO2018061797 A1 WO 2018061797A1 JP 2017033243 W JP2017033243 W JP 2017033243W WO 2018061797 A1 WO2018061797 A1 WO 2018061797A1
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- WIPO (PCT)
- Prior art keywords
- propellant
- surface treatment
- workpiece
- treatment method
- dimensional structure
- Prior art date
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y40/00—Auxiliary operations or equipment, e.g. for material handling
- B33Y40/20—Post-treatment, e.g. curing, coating or polishing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
- B24C1/00—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods
- B24C1/04—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods for treating only selected parts of a surface, e.g. for carving stone or glass
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
- B24C3/00—Abrasive blasting machines or devices; Plants
- B24C3/32—Abrasive blasting machines or devices; Plants designed for abrasive blasting of particular work, e.g. the internal surfaces of cylinder blocks
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/12—Both compacting and sintering
- B22F3/16—Both compacting and sintering in successive or repeated steps
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
- B24C1/00—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods
- B24C1/08—Methods for use of abrasive blasting for producing particular effects; Use of auxiliary equipment in connection with such methods for polishing surfaces, e.g. smoothing a surface by making use of liquid-borne abrasives
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
- B24C11/00—Selection of abrasive materials or additives for abrasive blasts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24C—ABRASIVE OR RELATED BLASTING WITH PARTICULATE MATERIAL
- B24C3/00—Abrasive blasting machines or devices; Plants
- B24C3/08—Abrasive blasting machines or devices; Plants essentially adapted for abrasive blasting of travelling stock or travelling workpieces
- B24C3/16—Abrasive blasting machines or devices; Plants essentially adapted for abrasive blasting of travelling stock or travelling workpieces for treating internal surfaces
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
Definitions
- the present invention relates to a surface treatment method for a metal three-dimensional structure, and more particularly to a surface treatment method for removing a surface defect of a metal three-dimensional structure manufactured by a three-dimensional modeling method.
- ⁇ ⁇ Casting and forging methods have been known for a long time as methods for manufacturing metal three-dimensional structures. These manufacturing methods are suitable for producing a relatively large three-dimensional structure in large quantities.
- a mold such as a mold, is required to form a desired shape, which is not suitable for manufacturing a three-dimensional structure having a possibility of shape change.
- structures that can be manufactured by a casting method or a forging method have limitations in shape and size. Further, in a structure having a complicated shape, it may be necessary to perform a cutting process after forming by a casting method or a forging method.
- Patent Document 1 As a processing method for removing surface defects of a three-dimensional structure manufactured by a three-dimensional modeling method, a processing method for removing a step between layers of the three-dimensional structure by injecting an abrasive to the three-dimensional structure is known.
- Patent Document 1 a processing method for a three-dimensional object manufactured from an epoxy resin by a three-dimensional optical modeling method, there is a problem that it cannot be applied to a metal object as it is. there were.
- the present invention has been made in view of the above problems, and an object thereof is to provide a surface treatment method for removing surface defects of a metal three-dimensional structure manufactured by a three-dimensional modeling method.
- a surface treatment method for removing surface defects of a metal three-dimensional structure manufactured by a three-dimensional modeling method Preparing the three-dimensional structure; Injecting a first propellant toward the surface of the three-dimensional structure and causing the first propellant to collide with the surface;
- the first propellant is a particle having a corner portion, and the corner portion removes a layered step on the surface of the three-dimensional structure.
- the first propellant is particles excluding metal.
- the first propellant is metallic particles having no oxide film formed on the surface.
- the first spray material has a Vickers hardness of Hv 2000 to 2500, and the collision energy when the first spray material collides with the surface to be processed is 2.9 ⁇ 10 ⁇ 8 to 6.2 ⁇ 10 ⁇ . 6 J.
- the first propellant has a Vickers hardness of Hv 500 to 800, and the collision energy when the first propellant collides with the surface to be processed is 1.0 ⁇ 10 ⁇ 6 to 3.2 ⁇ 10 ⁇ . 5 J.
- the first propellant has a Vickers hardness of Hv50 to 200, and the collision energy when the first propellant collides with the surface to be processed is 1.0 ⁇ 10 ⁇ 4 to 1.2 ⁇ 10 ⁇ . 3 J.
- the second propellant is a particle having no corners.
- the second propellant has a Vickers hardness of Hv 500 to 800, and the collision energy when the second propellant collides with the surface to be processed is 9.6 ⁇ 10 ⁇ 8 to 3.1 ⁇ 10 ⁇ . 6 J.
- Generating an air flow toward the lower side of the three-dimensional structure Rectifying the first spray material sprayed from above the three-dimensional structure toward the surface to be processed by the air flow.
- a surface treatment method for removing surface defects of a metal three-dimensional structure manufactured by a three-dimensional modeling method is provided.
- FIG. 1 shows schematic structure of the surface treatment apparatus used with the surface treatment method of the metal solid structure of preferable embodiment of this invention. It is a flowchart of the surface treatment method of the metal three-dimensional structure of preferable embodiment of this invention. It is a schematic diagram which shows the correlation of the collision energy in each condition of the surface treatment method of the metal three-dimensional structure of preferable embodiment of this invention. It is a perspective view which shows the external appearance of the workpiece
- FIG. 1 is a diagram showing a configuration of the surface treatment apparatus 1.
- the surface treatment apparatus 1 is a treatment apparatus that performs surface treatment by injecting an injection material onto the surface of a metal three-dimensional structure manufactured by a three-dimensional modeling method.
- the surface treatment apparatus 1 includes a housing 10 in which a processing chamber R for processing a workpiece W is provided.
- the housing 10 has a door 12, and an operator opens the door 12 and carries the workpiece W into and out of the processing chamber R.
- a storage hopper 14 for storing an injection material, a processing table 16 on which a workpiece W to be surface-treated is placed, and an injection material toward the workpiece W placed on the processing table 16. And a nozzle 18 for injecting water.
- the processing table 16 is placed on a moving mechanism 20 configured by a known mechanism such as an XY stage, and is configured to be freely movable in the X direction and the Y direction within the horizontal plane by the operation of the moving mechanism 20. Yes. As a result, the moving mechanism 20 can place the workpiece W placed on the processing table 16 at a desired position in the horizontal plane.
- a moving mechanism 20 configured by a known mechanism such as an XY stage, and is configured to be freely movable in the X direction and the Y direction within the horizontal plane by the operation of the moving mechanism 20. Yes.
- the moving mechanism 20 can place the workpiece W placed on the processing table 16 at a desired position in the horizontal plane.
- the moving mechanism 20 is arranged on a gantry 22 arranged at the lowermost part of the processing chamber R.
- the gantry 22 is composed of a plate-like member in which a large number of holes are formed.
- the nozzle 18 is disposed so as to face the workpiece W placed on the processing table 16 via the fixing jig 24.
- the fixing jig 24 is configured so that the distance between the nozzle 18 and the workpiece W can be freely adjusted.
- the nozzle 18 includes a nozzle holder 18a and an air nozzle 18b inserted into the nozzle holder 18a.
- the air nozzle 18b is in fluid communication with a compressor (not shown) via an air hose H1
- the nozzle holder 18a is in fluid communication with the storage hopper 14 via an injection material hose H2.
- the injection material When compressed air is injected from the air nozzle 18b by operating the compressor, the injection material is sucked into the air nozzle 18b through the nozzle holder 18a by the negative pressure generated in the air nozzle 18b by the flow of the compressed air, and compressed in the air nozzle 18b. It is mixed with air to form a solid-gas two-phase flow S, and is injected toward the workpiece W placed on the processing table 16.
- a suction type nozzle is employed as the nozzle 18, but a direct pressure type nozzle may be employed.
- a separation mechanism 26 composed of a cyclone classifier is provided above the storage hopper 14 disposed at the top of the processing chamber R.
- the separation mechanism 26 communicates with the bottom space of the processing chamber R (the lower space of the gantry 22) via the transport pipe P, and is configured to introduce the spray material sprayed onto the workpiece W for reuse.
- a cyclone classifier is used as the separation mechanism 26, but other wind classifiers and screen classifiers may be used.
- the separation mechanism 26 has a function of removing dust or the like that is not suitable for injection from the injection material introduced into the storage hopper 14. Specifically, for reuse, dust or the like is separated from the used injection material introduced through the transport pipe P from the bottom space of the processing chamber R, and only the reusable injection material is supplied to the storage hopper 14. It is configured.
- the surface treatment apparatus 1 of the present embodiment also includes a suction mechanism 28 that sucks the inside of the separation mechanism 26.
- a suction mechanism 28 that sucks the inside of the separation mechanism 26.
- dust or the like generated by the collision of the spray material injected onto the workpiece W and the spray material onto the workpiece W is reduced in the bottom space of the casing 10 (the lower portion of the gantry 22.
- the separation mechanism 26 is introduced from the space) through the transport pipe P.
- the surface treatment apparatus 1 of this embodiment includes a mechanism such as a separation mechanism 26 and a suction mechanism 28, and a control mechanism (not shown) that controls the operation of the apparatus.
- a control mechanism various arithmetic devices such as a personal computer, motion controllers such as a programmable logic controller (PLC) and a digital signal processor (DSP), a high-function mobile terminal, a high-function mobile phone, and the like are used.
- PLC programmable logic controller
- DSP digital signal processor
- the workpiece W to be surface-treated by the surface treatment method of the present embodiment is a metal three-dimensional structure manufactured by laminating aluminum powder while being cured in layers by a known three-dimensional modeling method.
- the work W has streaks that are stacking traces remaining on the surface, and has a rough surface.
- ⁇ S2 Prepare surface treatment device>
- the suction mechanism 28 is operated to suck the processing chamber R.
- the door 12 is opened, a predetermined amount of the first injection material is put into the processing chamber R, and the first injection material is transferred to the storage hopper 14 via the transport pipe P and the separation mechanism 26. Since the processing chamber R is sucked by the suction mechanism 28 via the separation mechanism 26, the processing chamber R becomes negative pressure, and outside air flows into the processing chamber R through a suction hole (not shown) provided to communicate with the outside. .
- the 1st injection material has a corner
- “Influencing the physical properties of the workpiece” means a state in which the material on the surface of the spray material is transferred to the workpiece, and the surface of the workpiece is coated with the transferred material.
- the coated state includes not only the state where the entire work surface is coated but also the state where a part of the work surface is coated (that is, the state where the transferred material is scattered on the work surface).
- the first propellant includes, for example, ceramic particles (alumina, silicon carbide, zircon, etc.), natural stone particles (emery, silica, diamond, etc.), plant particles (walnut shell, peach seeds, apricots) Or the like), resin particles (nylon, melamine, urea, etc.) and the like.
- Ceramic particles alumina, silicon carbide, zircon, etc.
- natural stone particles emery, silica, diamond, etc.
- plant particles walnut shell, peach seeds, apricots
- resin particles nylon, melamine, urea, etc.
- Use of particles other than metal can prevent the surface of the workpiece from being coated with a different metal.
- the oxide film may adhere to the work W depending on the physical properties of the work W. It is recommended to select metal particles that are not plated.
- the oxide film is not formed includes not only the case where the oxide film is not completely formed, but also the case where the film is formed to such an extent that the oxide film is not transferred to the workpiece W during the surface treatment. .
- the first propellant made of particles having a known true specific gravity. Further, the true specific gravity of the particles may be measured in advance by a known method such as a pycnometer method.
- an electromagnetic valve (not shown) provided in the path for supplying the compressed air to the nozzle 50 of the surface treatment apparatus 1 is opened, and the compressed air is supplied to the nozzle 18.
- the first injection material accommodated in the storage hopper 14 is sucked by the compressed air flow to the nozzle 18 and is injected toward the workpiece W from the tip of the nozzle 18.
- the injection speed of the first injection material is adjusted to a desired speed.
- the correlation between the physical properties (type, particle size, etc.) of the propellant, the jet pressure, and the jet speed is measured in advance, and the jet pressure is adjusted based on the result to obtain a desired jet speed.
- the speed of the spray material at the position where the workpiece is set by the particle velocity measurement method (Particle Image velocimetry: PIV) (the position immediately before the spray material collides with the workpiece), the physical properties of the spray material, and the injection pressure Measured in association with
- injection pressure is the injection pressure measured by a pressure gauge placed between the compressed air supply source and the nozzle.
- the injection pressure is controlled so as to obtain a desired injection speed by operating the injection valve based on the correlation between the injection pressure and the injection speed measured in advance.
- the electromagnetic valve provided in the path for supplying the compressed air to the nozzle 50 is closed, and the injection of the first injection material is stopped.
- the door 12 is opened, and the work W is placed on the processing table 16 and fixed. Thereafter, the fixing jig 22 is operated to adjust the distance between the nozzle 18 and the workpiece W, and the door 12 is closed.
- the workpiece W is moved relative to the nozzle so that the spray material is sprayed on the entire surface of the workpiece and the necessary surface treatment is performed.
- Surface treatment conditions such as the movement path, movement speed, and number of scans of the workpiece W are input to the control mechanism so that the workpiece W moves in this way.
- the first spray material collides with the workpiece. At this time, the stacking trace on the surface of the workpiece W is removed by the corners of the first propellant.
- the Vickers hardness in Table 1 is the Vickers hardness of the particle
- the collision energy is energy per particle of the propellant, and can be calculated based on the weight of individual particles constituting the first propellant and the speed immediately before these particles collide with the workpiece. it can.
- FIG. 3 shows numerical ranges of Vickers hardness and collision energy under each condition.
- the collision energy E of this embodiment is It is calculated by the following formula 1 where ⁇ is the true specific gravity of the propellant, L is the average particle diameter of the propellant, and v is the velocity of the propellant just before colliding with the workpiece.
- ⁇ is the true specific gravity of the propellant
- L is the average particle diameter of the propellant
- v is the velocity of the propellant just before colliding with the workpiece.
- calculation is performed by converting the shape of the propellant into a spherical shape having a particle diameter L.
- the surface treatment of Condition 1 is suitable for the surface treatment of a workpiece having a surface having relatively large minute irregularities (for example, a surface roughness Ra defined by JIS B0601: 2001 is 5.0 ⁇ m or more).
- the first propellant used in condition 1 has a strong cutting force, and can remove streaks that are stacking marks and cut the surface of the workpiece to reduce the surface roughness.
- Examples of the first propellant having this hardness include fused alumina particles and silicon carbide particles. Then, the properties and the injection speed of the first injection material are adjusted so that the collision energy is in the range of Condition 1, and the surface treatment is performed.
- the average particle diameter d50 of the first propellant may be selected from 15 to 75 ⁇ m, for example.
- the surface treatment of condition 2 is suitable for the surface treatment of a workpiece having a surface with relatively small roughness (for example, a surface roughness Ra defined in JIS B0601: 2001 is 1.0 to 5.0 ⁇ m).
- the first propellant having the hardness of Condition 2 include soda lime glass particles and zircon particles. Then, the properties and the injection speed of the first injection material are adjusted so that the collision energy is in the range of condition 2, and the surface treatment is performed.
- the average particle diameter d50 of the first propellant may be selected from 60 to 300 ⁇ m, for example.
- the surface treatment of condition 3 has a complicated shape and is suitable for the surface treatment of a workpiece requiring high dimensional accuracy.
- the workpiece having a complicated shape include a workpiece having irregularities and corners, a workpiece having a three-dimensionally complicated shape, and the like.
- work which comprises a sliding part, aircraft parts, parts of precision equipment, etc. are mentioned.
- the first propellant used in condition 3 has a low Vickers hardness, it deforms itself when it collides with the workpiece, and damage to the workpiece W is reduced. However, since the particles of the first propellant have corners, the stacking marks can be gradually removed.
- the first propellant having the hardness of Condition 3 include particles obtained by pulverizing apricot seeds, melamine resin, urea resin, and the like. The properties and spray speed of the spray material are adjusted, and surface treatment is performed.
- the average particle diameter d50 of the first propellant may be selected from 400 to 600 ⁇ m, for example.
- an air flow toward the bottom is generated by the suction mechanism 40.
- the first spray material sprayed from the nozzle 50 tends to spread throughout the processing chamber R, but is rectified in the direction toward the lower side of the workpiece W by this air flow.
- the amount of the first injection material that comes into contact with the workpiece W increases, so that surface treatment can be performed efficiently.
- work W increases, and surface treatment can be performed efficiently. .
- the first injection material after the injection material and the dust generated by the surface treatment are separated by the suction in the separation mechanism 26 by the suction mechanism 28. 26.
- the first injection material and dust are separated into a reusable first injection material and dust by the separation mechanism 26.
- the reusable first injection material is supplied to the storage hopper 14, and then transferred to the nozzle 18 and injected again.
- light dust is sucked by the suction mechanism 28 and collected by a collection filter (not shown) provided in the suction mechanism 28.
- the operator When the processing of the back side of the workpiece is necessary, the operator reverses the workpiece and the spray material is sprayed on the back side of the workpiece. Further, the spray material may be sprayed on the back surface of the work by another method.
- steps S1 to S4 correspond to the surface treatment method of the first embodiment of the present invention.
- ⁇ S5 Prepare surface treatment device> Similar to S2, the surface treatment apparatus is prepared.
- the second propellant used in the second surface treatment is preferably a particle having no corners.
- “without corners” includes both curved surfaces with rounded corners or all curved surfaces.
- the substantially spherical particle which is one form of the latter may be sufficient.
- the selection may be made in consideration of the possibility of affecting the physical properties of the workpiece.
- the collision energy when the second propellant collides with the surface to be processed is 9.6 ⁇ 10 ⁇ 8 to 3.1 ⁇ 10 ⁇ 6 J
- the average particle diameter d50 of the second propellant may be selected from 45 to 100 ⁇ m, for example.
- a three-dimensional structure W (FIG. 4) in which aluminum powder was formed into a substantially cylindrical shape was used as a workpiece.
- This three-dimensional structure W has a cylindrical shape of ⁇ 20 mm ⁇ 50 mm and is formed with eight grooves in the longitudinal direction. On the surface of the three-dimensional structure, streaks that are stacking traces extending in the longitudinal direction are formed, and the entire surface is rough.
- the surface-treated workpiece was observed with a microscope, and it was confirmed whether or not the stacking marks were removed.
- the evaluation criteria were as follows. ⁇ : Stacking marks have been removed. (Triangle
- Table 2 shows the results. (1) Removal of stacking marks Examples 1, 2, 4, and 6 were evaluated as ⁇ , and Examples 3 and 5 were evaluated as ⁇ . ⁇ Evaluation is a decrease in evaluation that does not cause a problem at a practical level, and it was found that the stacking marks could be removed well within the range of conditions 1 to 3 in Table 1. In particular, it was suggested that Condition 1 is more advantageous for removing the stacking marks.
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Abstract
Description
しかしながら、三次元立体造形法で得られた立体構造物には、層間の段差(積層痕)、表面のざらつき、ピンホール、光沢不足等の表面欠陥が有するという問題がある。
三次元造形法によって製造された金属製の立体構造物の表面欠陥を除去する表面処理方法であって、
前記立体構造物を準備する工程と、
前記立体構造物の表面に向かって第1の噴射材を噴射し、前記第1の噴射材を前記表面に衝突させる工程と、を含み、
前記第1の噴射材が角部を有する粒子であって、該角部によって立体構造物表面の層状の段差を除去する、
ことを特徴とする表面処理方法が提供される。
前記第1の噴射材は金属を除く粒子である。
前記第1の噴射材は表面に酸化皮膜が形成されていない金属質の粒子である。
前記第1の噴射材はビッカース硬さがHv2000~2500であり、且つ該第1の噴射材が被処理面に衝突した時の衝突エネルギーが2.9×10-8~6.2×10-6Jである。
前記第1の噴射材はビッカース硬さがHv500~800であり、且つ該第1の噴射材が被処理面に衝突した時の衝突エネルギーが1.0×10-6~3.2×10-5Jである。
前記第1の噴射材はビッカース硬さがHv50~200であり、且つ該第1の噴射材が被処理面に衝突した時の衝突エネルギーが1.0×10-4~1.2×10-3Jである。
前記立体構造物の被処理面に向かって第2の噴射材を噴射する工程を更に含み、
前記第2の噴射材は角部のない粒子である。
前記第2の噴射材はビッカース硬さがHv500~800であり、且つ該第2の噴射材が被処理面に衝突した時の衝突エネルギーが9.6×10-8~3.1×10-6Jである。
前記立体構造物の下方に向かう気流を発生させる工程と、
前記立体構造物の上方より被処理面に向けて噴射した前記第1の噴射材を前記気流によって整流する工程と、を含む。
まず、本発明の好ましい実施形態の金属製立体構造物の表面処理方法で使用される表面処理装置1の構成を説明する。図1は、表面処理装置1の構成を示す図面である。
なお、本実施態様では、ノズル18として吸引式ノズルが採用されているが、直圧式ノズルを採用してもよい。
次に、表面処理装置1を用いた本発明の第1の実施形態の表面処理方法について、図2のフローチャートに沿って説明する。
本実施態様の表面処理方法で表面処理されるワークWは、アルミニウム粉末を、公知の三次元造形法によって、層状に硬化させながら積層して製造された金属製の立体構造物である。このワークWは、表面に積層痕である筋が残存しており、さらに表面全体にざらつきがある。
吸引機構28を作動させ、処理室Rを吸引しておく。次いで、扉12を開き、所定量の第1の噴射材を処理室Rに投入し、輸送管P及び分離機構26を介して第1の噴射材を貯留ホッパ14に移送する。処理室Rは、分離機構26を介して、吸引機構28によって吸引されているので負圧となり、外部と連通するように設けられた吸引孔(図示せず)より外気が処理室Rに流入する。
「角部を有している」とは、噴射材が、円弧状の所謂丸面ではなく、鋭角あるいは鈍角の角を備えていることを意味している。また、噴射材の形状としては、異方形状、円柱形状、角柱形状、等角部を有する種々の形状が挙げられる。
「ワークの物性に影響を及ぼす」とは、噴射材表面の材質がワークに転写され、その転写物によってワークの表面がコーティングされた状態を意味する。なお、コーティングされた状態は、ワーク表面の全体がコーティングされた状態に加え、ワーク表面の一部がコーティングされている状態(即ち、転写物がワーク表面に点在している状態)も含む。
次いで、圧縮空気をノズル50に供給する経路に設けられた電磁弁が開かれ、ワークWに向けて第1の噴射材が噴射される。次いで、移動機構14が作動させられ、ワークWを載置した処理テーブル16および処理テーブル16に載置されているワークWが、ノズル18下方の所定位置に向かって水平移動させられる。
噴射材の真比重をρ、噴射材の平均粒子径をL、ワークに衝突する直前の噴射材の速度をv、とした下記の式1によって算出される。
ここでは、噴射材の形状を、粒子径Lである球状に換算し、算出が行なわれている。
条件1で使用される第1の噴射材は切削力が強く、積層痕である筋を除去すると共に、ワーク表面を切削して表面粗さを小さくすることができる。この硬さを持つ第1の噴射材は、例えば、溶融アルミナ粒子、炭化珪素粒子が挙げられる。そして、衝突エネルギーが、条件1の範囲になるように、第1の噴射材の性状及び噴射速度が調整され、表面処理が行われる。ここで、第1の噴射材の平均粒子径d50を、例えば15~75μmから選択してもよい。
条件2の硬さを有する第1の噴射材は、例えば、ソーダ石灰ガラス粒子やジルコン粒子が挙げられる。そして、衝突エネルギーが条件2の範囲になるように、第1の噴射材の性状及び噴射速度が調整され、表面処理が行われる。ここで、第1の噴射材の平均粒子径d50を、例えば60~300μmから選択してもよい。
複雑な形状のワークとしては、凹凸や隅角部を有するワーク、三次元的に複雑な形状を有するワーク等が挙げられる。また、高い寸法精度が求められるワークとしては、摺動部を構成するワーク、航空機部品、精密機器の部品等が挙げられる。
ワークWの所定の処理が完了すると、移動手段14の作動が停止され、圧縮空気をノズル50に供給する経路に設けられた電磁弁が閉じられ、表面処理装置の作動が停止させられる。その後、作業者が、扉12を開け、ワークWを回収する。さらに、必要に応じて、ワークWに付着した第1の噴射材や粉塵が除去される。
本発明の第2の実施形態は、上記第1の実施形態の表面処理方法で処理したワークWに対し、ワーク表面の光沢性向上や面粗度調整などによる意匠性改善が必要であるときに、第2の噴射材による第2の表面処理が付加的に行われる表面処理方法である。したがって、第2の実施形態は、上記第1の実施形態のS1ないしS4のステップと同様の処理の後に、S5ないしS7のステップが付加されたものである。
上記S2と同様に、表面処理装置の準備を行う。
第2の表面処理で使用される第2の噴射材は、角部のない粒子であることが好ましい。ここで、「角部のない」とは、角部が丸みを帯びた曲面である、もしくはすべてが曲面である、のいずれをも含む。そして、後者の一形態である略球形粒子であってもよい。
また、第1の噴射材の場合と同様、ワークの物性に影響を及ぼす可能性を考慮して選定するとよい。
上記S4と同様の操作が行われる。
○:積層痕が除去されている。
△:積層痕の段差は確認されないが、意匠として筋が確認される。
×:積層痕が除去されていない。
○:光沢性が高い。
△:光の反射が確認されるが、ややくすんでいる。
×:光の反射がない。
○:つるつるである。
△:手で撫でたときに引っ掛かりはないが、ややザラツキ感がある。
×:手で撫でたとき、抵抗を感じる。
(1)積層痕の除去
実施例1、2、4、6は○評価であり、実施例3及び5は△評価であった。△評価は実用レベルでは問題とならない程度の評価の低下であるので、表1における条件1~3の範囲においては、積層痕を良好に除去できることが分かった。特に、条件1の方が積層痕の除去には有利であることが示唆された。
実施例3、4、5は○評価であり、実施例1、2、6は△評価であった。△評価は実用レベルでは問題とならない程度の評価の低下であるので、表1における条件1~3の範囲においては、ワークに光沢性が得られることが分かった。特に、条件2の方が光沢性の向上には有利であることが示唆された。
実施例4、5、6は○評価であり、実施例1、3、4は△評価であった。△評価は実用レベルでは問題とならない程度の評価の低下であるので、表1における条件1~3の範囲においては、ワークに光沢性が得られることが分かった。特に、条件3の方が平滑性の向上には有利であることが示唆された。更に、第2の噴射材により表面処理を行った実施例7、8はいずれも○評価となったので、第2の噴射材による表面処理は、ワーク表面の平滑性の向上に有効であることが示唆された。
10:筐体
12:扉
14:貯留ホッパ
16:処理テーブル
18:ノズル
18a:ノズルホルダ
18b:エアノズル
20:移動機構
22:架台
24:固定治具
26:分離機構
W:ワーク
R:処理室
P:輸送管
H1:エアホース
H2:噴射材ホース
Claims (9)
- 三次元造形法によって製造された金属製の立体構造物の表面欠陥を除去する表面処理方法であって、
前記立体構造物を準備する工程と、
前記立体構造物の表面に向かって第1の噴射材を噴射し、前記第1の噴射材を前記表面に衝突させる工程と、を含み、
前記第1の噴射材が角部を有する粒子であって、該角部によって立体構造物表面の層状の段差を除去する、
ことを特徴とする表面処理方法。 - 前記第1の噴射材は金属を除く粒子である、
請求項1に記載の表面処理方法。 - 前記第1の噴射材は表面に酸化皮膜が形成されていない金属質の粒子である、
請求項1に記載の表面処理方法。 - 前記第1の噴射材はビッカース硬さがHv2000~2500であり、且つ該第1の噴射材が被処理面に衝突した時の衝突エネルギーが2.9×10-8~6.2×10-6Jである、
請求項1乃至3のいずれか1項に記載の表面処理方法。 - 前記第1の噴射材はビッカース硬さがHv500~800であり、且つ該第1の噴射材が被処理面に衝突した時の衝突エネルギーが1.0×10-6~3.2×10-5Jである、
請求項1乃至3のいずれか1項に記載の表面処理方法。 - 前記第1の噴射材はビッカース硬さがHv50~200であり、且つ該第1の噴射材が被処理面に衝突した時の衝突エネルギーが1.0×10-4~1.2×10-3Jである、
請求項1乃至3のいずれか1項に記載の表面処理方法。 - 前記立体構造物の被処理面に向かって第2の噴射材を噴射する工程を更に含み、
前記第2の噴射材は角部のない粒子である、
請求項1乃至6のいずれか1項に記載の表面処理方法。 - 前記第2の噴射材はビッカース硬さがHv500~800であり、且つ該第2の噴射材が被処理面に衝突した時の衝突エネルギーが9.6×10-8~3.1×10-6Jである、
請求項7に記載の表面処理方法。 - 前記立体構造物の下方に向かう気流を発生させる工程と、
前記立体構造物の上方より被処理面に向けて噴射した前記第1の噴射材を前記気流によって整流する工程と、を含む、
請求項1乃至8のいずれか1項に記載の表面処理方法。
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BR112019005618A BR112019005618A2 (pt) | 2016-09-28 | 2017-09-14 | método de tratamento de superfície. |
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JP2016153212A (ja) * | 2015-02-13 | 2016-08-25 | 株式会社リコー | 粉体除去装置、立体造形装置、粉体除去方法 |
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